Large bore plug valve

ABSTRACT

A plug valve including a valve body defining an internal cavity, a first passage, and a second passage, a plug defining a third passage and being rotatable within the internal cavity, and an insert extending within the internal cavity between the valve body and the plug. The insert defines an interior surface and an opening aligned with the first passage of the valve body. The insert may also define a sealing surface extending around the opening and standing in relief against the interior surface to sealingly engage the plug. In addition to, or instead of, the sealing surface, the insert may define a projection at least partially defining the interior surface. In addition, a boot may be connected to the valve body and interlocked with the projection to prevent, or at least reduce, rotation of the insert relative to the valve body when the plug rotates within the internal cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of, and priorityto, U.S. Application No. 62/354,101, filed Jun. 23, 2016, the entiredisclosure of which is hereby incorporated herein by reference.

This application also claims the benefit of the filing date of, andpriority to, U.S. Application No. 62/393,990, filed Sep. 13, 2016, theentire disclosure of which is hereby incorporated herein by reference.

This application also claims the benefit of the filing date of, andpriority to, U.S. Application No. 62/412,230, filed Oct. 24, 2016, theentire disclosure of which is hereby incorporated herein by reference.

This application also claims the benefit of the filing date of, andpriority to, U.S. Application No. 62/421,019, filed Nov. 11, 2016, theentire disclosure of which is hereby incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates in general to valves and, in particular,to a “large bore” plug valve used in oil or gas operations.

BACKGROUND

In oil or gas operations, one or more plug valves may be used to controlfluid flow; one such plug valve generally includes a valve body defininga pair of fluid passages intersecting an internal cavity. The internalcavity of the valve body accommodates a plug and an insert, which insertextends within an annular space between the plug and the valve body. Theplug and the insert include fluid passages that are adapted to besubstantially aligned with the fluid passages of the valve body. Theplug is adapted to rotate relative to the insert and the valve body toselectively permit fluid flow through the respective fluid passages ofthe valve body, the insert, and the plug. During operation, the insertis meant to seal against the plug and the valve body to thereby preventmigration of the fluid flow into the annular region between the plug andthe valve body. To establish a suitable seal between the insert and theplug, contact pressure between the insert and the plug must bemaintained above a threshold level.

During rotation of the plug, friction between the plug and the insertcan cause the insert to shift, turn, or rotate relative to the valvebody. The shifting, turning, or rotation of the insert relative to thevalve body causes misalignment between the fluid passages of the insert,the valve body, and the plug. This misalignment typically causes wear,erosion, or complete wash-out of the insert, the valve body, and/or theplug. In addition, the force required to maintain the contact pressurebetween the insert and the plug above the threshold level oftenincreases the amount of friction between the insert and the plug,thereby exacerbating the issue(s) described above. Indeed, in someinstances, excessive friction between the insert and the plug can makerotation of the plug relative to the insert difficult or impossible.These issues, among others, are particularly acute for “large bore” plugvalves in which the fluid passage of the plug has a relatively largediameter (e.g., about 5⅛ inches, greater than about 5⅛ inches, etc.).

Therefore, to make possible the manufacture of an effective and reliable“large bore” plug valve, what is needed is an apparatus, system, ormethod to address one or more of the foregoing issues, and/or one ormore other issues.

SUMMARY

In a first aspect, the present disclosure introduces an apparatus,including a valve body defining an internal cavity, a first passage, anda second passage; a plug defining a third passage and being rotatablewithin the internal cavity to selectively permit communication of afluid between the first and second passages via the third passage; andan insert extending within the internal cavity between the valve bodyand the plug, the insert defining a first opening aligned with the firstpassage of the valve body, a first interior surface, and a first sealingsurface extending around the first opening and standing in reliefagainst the first interior surface to sealingly engage the plug; whereinmigration of the fluid into an annular region between the insert and theplug is prevented, or at least reduced, by the sealing engagement of thefirst sealing surface with the plug.

In an embodiment, the insert includes a first segment including thefirst interior surface, the first opening, and the first sealingsurface.

In another embodiment, the insert further defines a second openingaligned with the second passage of the valve body, a second interiorsurface, and a second sealing surface extending around the secondopening and standing in relief against the second interior surface tosealingly engage the plug.

In yet another embodiment, migration of the fluid into the annularregion between the insert and the plug is prevented, or at leastreduced, by the respective sealing engagements of the first and secondsealing surfaces with the plug.

In certain embodiments, the insert includes a first segment includingthe first interior surface, the first opening, and the first sealingsurface, and a second segment including the second interior surface, thesecond opening, and the second sealing surface.

In an embodiment, the insert further includes third and fourth segmentsinterconnecting the first and second segments so that, in combination,the first, second, third, and fourth segments surround the plug.

In another embodiment, the apparatus further comprises a flow ironsection adapted to be positioned between a hydraulic fracturing pump anda wellhead, the flow iron section including one or more of apressurization manifold connected to the hydraulic fracturing pump, ahydraulic fracturing tree connected to the wellhead, and a distributionmanifold connected between the pressurization manifold and the hydraulicfracturing tree; wherein the valve body is connected to the flow ironsection so that the plug is rotatable within the valve body toselectively permit communication of a hydraulic fracturing fluid fromthe hydraulic fracturing pump to the wellhead via at least the flow ironsection and the third passage.

In a second aspect, the present disclosure introduces an apparatus,including a valve body defining an internal cavity, a first passage, anda second passage; a plug defining a third passage and being rotatablewithin the internal cavity to selectively permit communication of afluid between the first and second passages via the third passage; aninsert extending within the internal cavity between the valve body andthe plug, the insert defining a first opening aligned with the firstpassage of the valve body, a first interior surface, and a firstprojection at least partially defining the first interior surface; and aboot connected to the valve body and interlocked with the firstprojection of the insert to prevent, or at least reduce, rotation of theinsert relative to the valve body when the plug rotates within theinternal cavity.

In an embodiment, the first projection includes first and second sidesurfaces, and the boot includes first and second edge portions extendingadjacent the first and second side surfaces, respectively, of the firstprojection.

In another embodiment, the boot further includes a third edge portionextending between the first and second edge portions and adjacent thefirst interior surface of the insert.

In yet another embodiment, the insert further defines a second openingaligned with the second passage of the valve body, a second interiorsurface, and a second projection at least partially defining the secondinterior surface; and the boot is interlocked with the second projectionof the insert to prevent, or at least reduce, rotation of the insertrelative to the valve body when the plug rotates within the internalcavity.

In certain embodiments, the first projection includes first and secondside surfaces, and the boot includes first and second edge portionsextending adjacent the first and second side surfaces, respectively, ofthe first projection; and the second projection includes third andfourth side surfaces, and the boot includes third and fourth edgeportions extending adjacent the third and fourth side surfaces,respectively, of the second projection.

In an embodiment, the boot further includes a fifth edge portionextending between the first and second edge portions and adjacent thefirst interior surface of the insert; and a sixth edge portion extendingbetween the third and fourth edge portions and adjacent the secondinterior surface of the insert.

In another embodiment, the insert includes a first segment including thefirst interior surface, the first projection, and the first opening, anda second segment including the second interior surface, the secondprojection, and the second opening.

In yet another embodiment, the insert further includes third and fourthsegments interconnecting the first and second segments so that, incombination, the first, second, third, and fourth segments surround theplug.

In certain embodiments, the apparatus further comprises a flow ironsection adapted to be positioned between a hydraulic fracturing pump anda wellhead, the flow iron section including one or more of apressurization manifold connected to the hydraulic fracturing pump, ahydraulic fracturing tree connected to the wellhead, and a distributionmanifold connected between the pressurization manifold and the hydraulicfracturing tree; and wherein the valve body is connected to the flowiron section so that the plug is rotatable within the valve body toselectively permit communication of a hydraulic fracturing fluid fromthe hydraulic fracturing pump to the wellhead via at least the flow ironsection and the third passage.

In a third aspect, the present disclosure introduces an apparatus,including a flow iron section adapted to be positioned between ahydraulic fracturing pump and a wellhead, the flow iron sectionincluding one or more of a pressurization manifold connected to thehydraulic fracturing pump, a hydraulic fracturing tree connected to thewellhead, and a distribution manifold connected between thepressurization manifold and the hydraulic fracturing tree; and a plugvalve connected to the flow iron section, the plug valve including avalve body and a plug, the plug defining a first passage and beingrotatable within the valve body to selectively permit communication of ahydraulic fracturing fluid from the hydraulic fracturing pump to thewellhead via at least the flow iron section and the first passage, thefirst passage having an inner diameter that is equal to, or greaterthan, about 5⅛ inches.

In an embodiment, the valve body further defines second and thirdpassages configured to communicate with one another via the firstpassage of the plug when communication of the hydraulic fracturing fluidis selectively permitted from the hydraulic fracturing pump to thewellhead via at least the flow iron section and the first passage.

In another embodiment, the plug valve further includes an insertextending between the valve body and the plug, the insert defining anopening aligned with the first passage of the valve body, an interiorsurface, and a sealing surface extending around the opening and standingin relief against the interior surface to sealingly engage the plug.

In yet another embodiment, the plug valve further includes an insertextending within the valve body between the valve body and the plug, theinsert defining an opening aligned with the first passage of the valvebody, an interior surface, and a projection at least partially definingthe interior surface; and a boot connected to the valve body andinterlocked with the projection of the insert to prevent, or at leastreduce, rotation of the insert relative to the valve body when the plugrotates within the valve body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view illustrating a plug valve, according toone or more embodiments of the present disclosure.

FIG. 1B is an exploded perspective view illustrating internal componentsof the plug valve of FIG. 1A, including, inter alia, a plug, an inletsegment, an outlet segment, and a boot, according to one or moreembodiments of the present disclosure.

FIG. 2 is a cross-sectional view of the plug valve of FIG. 1A, includingthe plug, the inlet segment, the outlet segment, and the boot, accordingto one or more embodiments of the present disclosure.

FIG. 3 is an enlarged view of the plug valve of FIG. 2, according to oneor more embodiments of the present disclosure.

FIG. 4 is another enlarged view of the plug valve of FIG. 2, accordingto one or more embodiments of the present disclosure.

FIGS. 5-8 are rear perspective, front perspective, top plan, and bottomplan views, respectively, of the inlet segment of FIGS. 1B and 2,according to one or more embodiments of the present disclosure.

FIGS. 9 and 10 are perspective views illustrating the plug, the inletsegment, and the outlet segment in different stages of assembly,according to one or more embodiments of the present disclosure.

FIG. 11 is a perspective view of the boot of FIGS. 1A and 2, accordingto one or more embodiments of the present disclosure.

FIG. 12 is an enlarged cross-sectional view of the plug valve of FIG. 2in a first operational configuration, according to one or moreembodiments of the present disclosure.

FIG. 13 is a sectional view of the plug valve taken along the line 13-13of FIG. 12, according to one or more embodiments of the presentdisclosure.

FIG. 14 is a sectional view of the plug valve taken along the line 14-14of FIG. 12, according to one or more embodiments of the presentdisclosure.

FIG. 15 is an enlarged view of the plug valve similar to that shown inFIG. 12, except that the plug valve is in a second operationalconfiguration, according to one or more embodiments of the presentdisclosure.

FIG. 16 is a sectional view of the plug valve taken along the line 16-16of FIG. 15, according to one or more embodiments of the presentdisclosure.

FIG. 17 is a schematic illustration of a hydraulic fracturing system,the hydraulic fracturing system including a hydraulic fracturing pump, aflow iron section, and a wellhead, according to one or more embodimentsof the present disclosure.

FIG. 18 is an elevational view of the plug valve of FIGS. 1-16 connectedbetween a pair of flow-line components, which flow-line components arepart of the flow iron section of FIG. 17, according to one or moreembodiments of the present disclosure.

DETAILED DESCRIPTION

Turning initially to FIGS. 1A and 1B, an example embodiment of a plugvalve, generally referred to by the reference numeral 10, isillustrated. As shown in FIG. 1A, the plug valve 10 includes a valvebody 12, an actuator 14, an actuator plate 16, and a cover plate 18. Theactuator 14 is connected to the actuator plate 16 via a plurality offasteners 20, and the actuator plate 16 is connected to the valve body12. The cover plate 18 is connected to the valve body 12 via a pluralityof fasteners 22, opposite the actuator plate 16. In some embodiments,the cover plate 18 is considered part of the valve body 12. The plugvalve 10 includes one or more lubrication fittings 24 connected to thevalve body 12 to facilitate lubrication of internal component(s) of theplug valve 10. The actuator 14 is adapted to actuate the plug valve 10between an open configuration in which fluid flow is permitted throughthe plug valve 10 and a closed configuration in which fluid flow throughthe plug valve 10 is prevented, or at least reduced.

The valve body 12, the actuator 14, the actuator plate 16, and the coverplate 18 are omitted from view in FIG. 1B to more clearly illustrate theinternal components of the plug valve 10. Turning to FIG. 1B, the plugvalve 10 further includes a plug 26 and an insert 28, which plug 26defines an exterior surface 30 and a fluid passage 32 extendingtransversely therethrough. The insert 28 is adapted to extend about andsealingly engage the exterior surface 30 of the plug 26. The insert 28includes an inlet segment 34, an outlet segment 36, and side segments 38a and 38 b. The inlet segment 34 includes an inlet opening 40 and isadapted to accommodate an inlet seal 42 around the inlet opening 40. Theinlet seal 42 is adapted to engage the valve body 12. The outlet segment36 includes an outlet opening 44 and is adapted to accommodate an outletseal 46 around the outlet opening 44. The outlet seal 46 is adapted toengage the valve body 12. The side segments 38 a and 38 b are adapted toconnect the inlet segment 34 to the outlet segment 36 to thereby place acompressive load on the plug 26. The plug valve 10 includes alignmentdowels 48 a and 48 b to facilitate the alignment of the inlet and outletopenings 40 and 44 within the valve body 12.

The plug valve 10 also includes a drive gear 50 and an adapter 52 viawhich the actuator 14 is adapted to be operably coupled to the plug 26.The adapter 52 is adapted to be supported within the valve body 12 via abearing 54 and a spacer 56. The spacer 56 is adapted to accommodate anouter seal 58 and an outer backup ring 60 so that the outer seal 58engages the spacer 56 and the valve body 12. The spacer 56 is furtheradapted to accommodate an inner seal 62 and an inner backup ring 64 sothat the inner seal 62 engages the spacer 56 and the adapter 52. Thevalve body 12 is adapted to accommodate a wiper seal 66 so that thewiper seal 66 engages the adapter 52 and the valve body 12 to preventdrainage of fluid (e.g., lubricating fluid) from the actuator 14 intothe valve body 12. The cover plate 18 is adapted to accommodate a seal68 and a backup ring 70 so that the seal 68 engages the cover plate 18and the valve body 12. The plug valve 10 includes a boot 72 adapted tobe connected to the cover plate 18 via a plurality of fasteners 74.Thus, the boot 72 is adapted to be connected to the valve body 12 inthose embodiments in which the cover plate 18 is considered part of thevalve body 12. The boot 72 is adapted to interlock with the insert 28 tothereby prevent, or at least reduce, rotation of the insert 28 relativeto the valve body 12 when the plug 26 rotated.

Turning to FIG. 2, with continuing reference to FIGS. 1A and 1B, it canbe seen that the valve body 12 defines an internal cavity 76, an inletpassage 78, an outlet passage 80, an actuator bore 82, and an accessport 84. The inlet passage 78 permits fluid communication between thevalve body 12 and an adjacent flow-line component such as, for example,the flow-line component 134 shown in FIGS. 18A and 18B, which will bediscussed in further detail below. The valve body 12 includes a flange86 around the inlet passage 78 to facilitate connection of the valvebody 12 to the adjacent flow-line component. The flange 86 includes athrough-hole pattern (visible in FIG. 1A; or a threaded-hole pattern).The outlet passage 80 permits fluid communication between the valve body12 and another adjacent flow-line component such as, for example, theflow-line component 136 shown in FIGS. 18A and 18B, which will bediscussed in further detail below. The valve body 12 includes a flange88 around the outlet passage 80 to facilitate connection of the plugvalve 10 to the another adjacent flow-line component. The flange 88includes a through-hole pattern (visible in FIG. 1A; or a threaded-holepattern). In some embodiments, one or both of the flanges 86 and 88 areomitted and replaced with another type of fluid-line connector such as,for example, the male half of a hammer union, the female half of ahammer union, a hammerless union, another fluid-line connector, or anycombination thereof.

The plug 26 extends within the internal cavity 76 of the valve body 12and is coupled to the actuator 14 via the drive gear 50 and the adapter52. The adapter 52 is supported within the actuator bore 82 via thebearing 54 and the spacer 56. The wiper seal 66 seals against theadapter 52 and the valve body 12 to thereby prevent drainage of fluid(e.g., lubricating fluid) from the actuator 14 into the valve body 12.The insert 28 extends about and seals against the exterior surface 30 ofthe plug 26. The inlet and outlet openings 40 and 44 are aligned withthe inlet and outlet passages 78 and 80, respectively, of the valve body12. The actuator 14 is operable to rotate the drive gear 50, the adapter52, and the plug 26 relative to the valve body 12 to thereby actuate theplug 26 between the open configuration and the closed configuration. Asshown in FIG. 2, the fluid passage 32 of the plug 26 is adapted to bealigned with the inlet and outlet openings 40 and 44 of the insert 28and the inlet and outlet passages 78 and 80 of the valve body 12 whenthe plug valve 10 is in the open configuration. In some embodiments, thefluid passage 32 has an inner diameter of about 5⅛ inches, of about 71/16 inches, or ranging from about 5⅛ inches to about 7 1/16 inches.

Turning to FIG. 3, with continuing reference to FIG. 2, it can be seenthat the inlet segment 34 accommodates the inlet seal 42 around theinlet opening 40 in a manner that seals the inlet seal 42 against thevalve body 12 around the inlet passage 78. Likewise, the outlet segment36 accommodates the outlet seal 46 around the outlet opening 44 in amanner that seals the outlet seal 46 against the valve body 12 aroundthe outlet passage 80 (visible in FIG. 2). The cover plate 18 extendsinto the access port 84 and accommodates the seal 68 and the backup ring70 so that the seal 68 seals against the valve body 12. The boot 72 isconnected to the cover plate 18 via the plurality of fasteners 74 in amanner that permits interlocking of the insert 28 with the boot 72.Thus, the boot 72 is connected to the valve body 12 in those embodimentsin which the cover plate 18 is considered part of the valve body 12.Alternatively, although described herein as being connected to the coverplate 18, the boot 72 may instead be connected directly to the valvebody 12.

Turning to FIG. 4, with continuing reference to FIG. 2, the spacer 56accommodates the outer seal 58 and the outer backup ring 60 so that theouter seal 58 seals against the valve body 12. The spacer 56 alsoaccommodates the inner seal 62 and the inner backup ring 64 so that theinner seal 62 seals against the adapter 52.

The outlet segment 36 is substantially identical to the inlet segment 34and, therefore, in connection with FIGS. 5-8, only the inlet segment 34will be described in detail below; however, the description below alsoapplies to the outlet segment 36. Turning to FIGS. 5-8, the inletsegment 34 includes a concave interior surface 90 and a convex exteriorsurface 92. The inlet opening 40 extends through the concave interiorsurface 90 and the convex exterior surface 92. The inlet segment 34includes a concave sealing surface 94 formed around the inlet opening40. The concave sealing surface 94 stands in relief against the concaveinterior surface 90 to seal against the exterior surface 30 of the plug26. The inlet segment 34 includes a sealing groove 96 formed in theconvex exterior surface 92 and around the inlet opening 40. The sealinggroove 96 accommodates the inlet seal 42. The convex exterior surface 92also includes longitudinally-extending grooves 98 a and 98 b formedtherein to facilitate connection of the inlet segment 34 to the sidesegments 38 a and 38 b, respectively. The inlet segment 34 includes analignment notch 100 to accommodate the dowel 92 a when the plug valve 10is assembled. The inlet segment 34 also includes a projection 102opposite the alignment notch 100. The projection 102 includes sidesurfaces 104 a and 104 b. In some embodiments, the side surfaces 104 aand 104 b are spaced in a parallel relation. The projection 102 isadapted to interlock with the boot 72 to thereby prevent, or at leastreduce, rotation of the insert 28 relative to the valve body 12 when theplug 26 is actuated between the open configuration and the closedconfiguration, as will be discussed in further detail below.

Turning to FIGS. 9 and 10, with continuing reference to FIGS. 5-8, anexample embodiment of the manner in which the compressive load is placedon the plug 26 by the insert 28 is illustrated. To begin with, the inletand outlet segments 34 and 36 are engaged with the exterior surface 30of the plug 26. Subsequently, the side segment 38 a is adapted to beconnected to the longitudinally-extending groove 98 a of the inletsegment 34 and a longitudinally-extending groove of the outlet segment36 (which is analogous to the longitudinally-extending groove 98 b ofthe inlet segment 34). Moreover, the side segment 38 b is adapted to beconnected to the longitudinally-extending groove 98 b of the inletsegment 34 and a longitudinally-extending groove of the outlet segment36 (which is analogous to the longitudinally-extending groove 98 a ofthe inlet segment 34). The connection of the side segments 38 a and 38 bwith the inlet and outlet segments 34 and 36 is adapted to place theside segments 38 a and 38 b in tension between the inlet and outletsegments 34 and 36 so that the compressive load is placed on the plug 26by the inlet and outlet segments 34 and 36. The tensioning of the sidesegments 38 a and 38 b between the inlet and outlet segments 34 and 36is adapted to seal the concave sealing surface 94 of the inlet segment34 against the exterior surface 30 of the plug 26, and to seal a concavesealing surface of the outlet segment 36 (which is analogous to theconcave sealing surface 94 of the inlet segment 34) against the exteriorsurface 30 of the plug 26, opposite the inlet segment 34. Duringoperation, the sealing of the inlet and outlet segments 34 and 36against the plug 26 is aided by a lubricating fluid (not shown) providedat the interface between the plug 26 and the inlet and outlet segments34 and 36 via, for example, the lubrication fitting(s) 24 (FIG. 1A). Theside segments 38 a and 38 b are spaced apart from the plug 26 when theside segments 38 a and 38 b are tensioned between the inlet and outletsegments 34 and 36 (i.e., such that the side segments 38 a and 38 b donot contact the plug 26).

Although the side segments 38 a and 38 b have been described herein asbeing connected to the inlet segment 34's longitudinally-extendinggrooves 98 a and 98 b and the outlet segment 36'slongitudinally-extending grooves (which are analogous to the inletsegment 34's longitudinally-extending grooves 98 a and 98 b), the sidesegments 38 a and 38 b may be connected to the side segments 38 a and 38b in another suitable manner. Moreover, although the compressive loadapplied to the plug 26 by the inlet and outlet segments 34 and 36 hasbeen described herein as being provided by tensioning of the sidesegments 38 a and 38 b between the inlet and outlet segments 34 and 36,the side segments 38 a and 38 b may alternatively be omitted and thecompressive load applied to the plug 26 by the inlet and outlet segments34 and 36 may be provided by another suitable structure or mechanism.

Turning to FIG. 11, with continuing reference to FIGS. 5-10, an exampleembodiment of the boot 72 is illustrated. The boot 72 includes edgeportions 106 a and 106 b and edge portions 108 a-d. In some embodiments,the edge portions 106 a and 106 b are convex. In some embodiments, theedge portions 108 a-d are straight. In some embodiments, the edgeportions 106 a and 106 b are convex and the edge portions 108 a-d arestraight. The boot 72 includes a through-hole pattern 110 (e.g.,including countersunk through-holes) to facilitate connection of theboot 72 to the cover plate 18.

The edge portions 108 a and 108 b of the boot 72 are adapted to extendadjacent the side surfaces 104 a and 104 b, respectively, of the inletsegment 34. In some embodiments, the edge portions 108 a and 108 b arespaced in a parallel relation. Moreover, the edge portion 106 a isadapted to extend adjacent the concave interior surface 90 of the inletsegment 34 when the edge portions 108 a and 108 b of the boot 72 extendadjacent the side surfaces 104 a and 104 b, respectively, of the inletsegment 34. In this manner, the boot 72 is adapted to interlock with theprojection 102 of the inlet segment 34.

The edge portions 108 c and 108 d of the boot 72 are adapted to extendadjacent surfaces, respectively, of the outlet segment 36. In someembodiments, the edge portions 108 c and 108 d are spaced in a parallelrelation. The surfaces of the outlet segment 36 with which the edgeportions 108 c and 108 d of the boot 72 are adapted to extend adjacentare analogous to the side surfaces 104 a and 104 b of the inlet segment34. Moreover, the edge portion 106 b of the boot 72 is adapted to extendadjacent a concave interior surface of the outlet segment 36 when theedge portions 108 c and 108 d extend adjacent the surfaces of the outletsegment 36. The concave interior surface of the outlet segment 36 withwhich the edge portion 106 b of the boot 72 is adapted to extendadjacent is analogous to the concave interior surface 90 of the inletsegment 34. In this manner, the boot 72 is adapted to interlock with aprojection of the outlet segment 36 that is analogous to the projection102 of the inlet segment 34.

Turning to FIGS. 12-16, in operation, the plug valve 10 is actuablebetween the open configuration (shown in FIGS. 12-14) and the closedconfiguration (shown in FIGS. 15 and 16). Turning to FIGS. 12 and 13, inthe open configuration, the fluid passage 32 of the plug 26 is alignedwith the inlet and outlet openings 40 and 44 of the insert 28 and theinlet and outlet passages 78 and 80 of the valve body 12 so that fluidflow is permitted through the plug valve 10, as indicated by arrow(s)112. The inlet seal 42 engages the valve body 12 around the inletpassage 78 to thereby prevent migration of the fluid 112 into an annularregion between the insert 28 and the valve body 12 as the fluid 112enters the fluid passage 32 via the inlet passage 78 and the inletopening 40. To prevent migration of the fluid 112 into an annular regionbetween the insert 28 and the plug 26, the concave sealing surface 94 ofthe inlet segment 34 seals against the exterior surface 30 of the plug26 around the fluid passage 32. In addition, the outlet seal 46 engagesthe valve body 12 around the outlet passage 80 to thereby preventmigration of the fluid 112 into the annular region between the insert 28and the valve body 12 as the fluid 112 exits the fluid passage 32 viathe outlet opening 44 and the outlet passage 80. To prevent migration ofthe fluid 112 into the annular region between the insert 28 and the plug26, the concave sealing surface of the outlet segment 36 (which isanalogous to the concave sealing surface 94 of the inlet segment 34)seals against the exterior surface 30 of the plug 26 around the fluidpassage 32. The sealing of the inlet and outlet segments 34 and 36against the plug 26 is aided by the lubricating fluid (not shown)provided at the interface between the plug 26 and the inlet and outletsegments 34 and 36 via, for example, the lubrication fitting(s) 24 (FIG.1A).

Turning to FIG. 14, it can be seen that the projection 102 of the inletsegment 34 and the projection of the outlet segment 36 (which isanalogous to the projection 102 of the inlet segment 34) each interlockwith the boot 72 to thereby prevent, or at least reduce, rotation of theinsert 28 relative to the valve body 12. More particularly, the edgeportions 108 a and 108 b of the boot 72 extend adjacent the sidesurfaces 104 a and 104 b, respectively, of the inlet segment 34, and theedge portion 106 a of the boot 72 extends adjacent the concave interiorsurface 90 of the inlet segment 34. In this manner, the boot 72interlocks with the projection 102 of the inlet segment 34. In addition,the edge portions 108 c and 108 d of the boot 72 extend adjacent thesurfaces, respectively, of the outlet segment 36 (which are analogous tothe side surfaces 104 a and 104 b of the inlet segment 34), and the edgeportion 106 b of the boot 72 extends adjacent the concave interiorsurface of the outlet segment 36 (which is analogous to the concaveinterior surface 90 of the inlet segment 34). In this manner, the boot72 interlocks with the projection of the outlet segment 36 (which isanalogous to the projection 102 of the inlet segment 34) to prevent, orat least reduce, rotation of the insert 28 relative to the valve body12. As a result, the substantial alignment between the inlet and outletopenings 40 and 44 of the insert 28 and the inlet and outlet passages 78and 80, respectively, of the valve body 12 is maintained during theactuation of the plug valve 10 between the open and closedconfigurations.

Turning to FIGS. 15 and 16, in the closed configuration, the plug 26 isrotated to prevent, or at least reduce, communication of the fluid 112from the inlet passage 78 to the outlet passage 80 of the valve body 12.To actuate the plug 26 from the open configuration to the closedconfiguration, the actuator 14 rotates the plug 26 (via the drive gear50 and the adapter 52) so that the fluid passage 32 of the plug 26 is nolonger aligned with the inlet and outlet openings 40 and 44 of theinsert 28 or the inlet and outlet passages 78 and 80 of the valve body12. Instead, the exterior surface 30 of the plug 26 is substantiallyaligned with the inlet and outlet openings 40 and 44 of the insert 28and the inlet and outlet passages 78 and 80 of the valve body 12 tothereby block communication of the fluid 112 from the inlet passage 78to the outlet passage 80 of the valve body 12. The fluid 112 within theinlet passage 78 and the inlet opening 40 is prevented from migratinginto the annular region between the insert 28 and the valve body 12 bythe sealing engagement of the inlet seal 42 against the valve body 12around the inlet passage 78. More particularly, to prevent migration ofthe fluid 112 into the annular region between the insert 28 and the plug26, the concave sealing surface 94 of the inlet segment 34 seals againstthe exterior surface 30 of the plug 26. The lubricating fluid (notshown) provided at the interface between the plug 26 and the inletsegment 34 (via, for example, the lubrication fitting(s) 24 (FIG. 1A))aids with the sealing engagement of the inlet segment 34 against theplug 26. The tensioning of the side segments 38 a and 38 b between theinlet and outlet segments 34 and 36 prevents the fluid 112 in the inletpassage 78 from unsealing the concave sealing surface 94 of the inletsegment 34 from the exterior surface 30 of the plug 26.

The manner in which the concave sealing surface 94 stands in reliefagainst the concave interior surface 90 of the inlet segment 34 reducesthe contact area between the insert 28 and the plug 26. Similarly, themanner in which the outlet segment 36's concave sealing surface (whichis analogous to the concave sealing surface 94 of the inlet segment 34)stands in relief against the concave interior surface (which isanalogous to the concave interior surface 90 of the inlet segment 34)reduces the contact area between the insert 28 and the plug 26. Inaddition, the spacing apart of the side segments 38 a and 38 b from theplug 26 when the side segments 38 a and 38 b are tensioned between theinlet and outlet segments 34 and 36 reduces the contact area between theinsert 28 and the plug 26.

In some embodiments, reducing the contact area between the insert 28 andthe plug 26 increases the contact pressure between the insert 28 and theplug 26. In some embodiments, reducing the contact area between theinsert 28 and the plug 26 decreases the amount of force required tomaintain the contact pressure between the insert 28 and the plug 26above the minimum threshold required to establish a suitable seal withthe plug 26. In some embodiments, reducing the contact area between theinsert 28 and the plug 26 enables the side segments 38 a and 38 b (oranother suitable structure or mechanism) to maintain the contactpressure between the insert 28 and the plug 26 above the minimumthreshold required to establish a suitable seal with the plug 26.

In some embodiments, reducing the contact area between the insert 28 andthe plug 26 decreases the amount of friction between the plug 26 and theinsert 28. In some embodiments, reducing the contact area between theinsert 28 and the plug 26 mitigates any shifting, turning, or rotationof the insert 28 relative to the valve body 12. In some embodiments,reducing the contact area between the insert 28 and the plug 26prevents, or at least reduces, misalignment between the inlet and outletopenings 40 and 44 of the insert 28 and the inlet and outlet passages 78and 80 of the valve body 12. In some embodiments, reducing the contactarea between the insert 28 and the plug 26 prevents, or at leastreduces, wear, erosion, or complete wash-out of the plug 26, the insert28, and/or the valve body 12.

In some embodiments, the reduced contact area between the insert 28 andthe plug 26 makes possible the manufacture of an effective and reliable“large bore” plug valve 10 in which the fluid passage 32 of the plug 26has an inner diameter of: about 5⅛ inches, greater than about 5⅛ inches,ranging from about 5⅛ inches to about 7 1/16 inches, about 7 1/16inches, or greater than about 7 1/16 inches. In some embodiments, thereduced contact area between the insert 28 and the plug 26 permitsrelaxed tolerances during the manufacture of the insert 28 whilemaintaining the insert 28's capability to matingly engage the plug 26 sothat an effective seal is maintained therebetween.

In some embodiments, the engagement of the boot 72 with the inletsegment 34's projection 102 and/or the outlet segment 36's projection(which is analogous to the projection 102) mitigates any shifting,turning, or rotation of the insert 28 relative to the valve body 12. Insome embodiments, the engagement of the boot 72 with the inlet segment34's projection 102 and/or the outlet segment 36's projection (which isanalogous to the projection 102) prevents, or at least reduces,misalignment between the inlet and outlet openings 40 and 44 of theinsert 28 and the inlet and outlet passages 78 and 80 of the valve body12. In some embodiments, the engagement of the boot 72 with the inletsegment 34's projection 102 and/or the outlet segment 36's projection(which is analogous to the projection 102) prevents, or at leastreduces, wear, erosion, or complete wash-out of the plug 26, the insert28, and/or the valve body 12.

In some embodiments, the engagement of the boot 72 with the inletsegment 34's projection 102 and/or the outlet segment 36's projection(which is analogous to the projection 102) makes possible themanufacture of an effective and reliable “large bore” plug valve 10 inwhich the fluid passage 32 of the plug 26 has an inner diameter of:about 5⅛ inches, greater than about 5⅛ inches, ranging from about 5⅛inches to about 7 1/16 inches, about 7 1/16 inches, or greater thanabout 7 1/16 inches.

Turning to FIG. 17, with continuing reference to FIGS. 1-16, a hydraulicfracturing system, generally referred to by the reference numeral 114,is illustrated. The hydraulic fracturing system 114 includes a flow ironsection 116 positioned between a hydraulic fracturing pump 118 and awellhead 120. The flow iron section 116 includes one or more of: apressurization manifold 122 connected to the hydraulic fracturing pump118, a hydraulic fracturing tree 124 connected to the wellhead 120, anda distribution manifold 126 connected between the pressurizationmanifold 122 and the hydraulic fracturing tree 124. The pressurizationmanifold 122 includes a low pressure section 128 connected between afluid source 130 and the hydraulic fracturing pump 118, and a highpressure section 132 connected between the hydraulic fracturing pump 118and the distribution manifold 126. In addition to, or instead of, thehydraulic fracturing pump 118, the hydraulic fracturing system 114 mayinclude other hydraulic fracturing pump(s) (not shown) to facilitatepressurization of the hydraulic fracturing fluid from the low pressuresection 128 and communication of the pressurized hydraulic fracturingfluid to the high pressure section 132. The wellhead 120 is located atthe top or head of an oil and gas wellbore (not shown), which penetratesone or more subterranean formations (not shown). In addition to, orinstead of the, wellhead to which the fracturing tree is connected, thehydraulic fracturing system 114 may also include one or more wellheads(not shown) to which fracturing trees (not shown) are connected; thedistribution manifold 126 facilitates communication of the pressurizedhydraulic fracturing fluid to such wellhead(s) via the correspondingfracturing tree(s).

In operation, the hydraulic fracturing fluid is communicated from thehydraulic fracturing pump 118 to the wellhead 120 via at least the flowiron section 116 to thereby facilitate hydraulic fracturing of thesubterranean formation(s). More particularly, the hydraulic fracturingfluid is communicated from the fluid source 130 to the low pressuresection 128 of the pressurization manifold 122. The hydraulic fracturingpump 118 receives the hydraulic fracturing fluid from the low pressuresection 128, pressurizes the hydraulic fracturing fluid, andcommunicates the pressurized hydraulic fracturing fluid to the highpressure section 132. The high pressure section 132 communicates thepressurized hydraulic fracturing fluid from the hydraulic fracturingpump 118 to the distribution manifold 126. The distribution manifold 126communicates the pressurized hydraulic fracturing fluid from the highpressure section 132 of the pressurization manifold 122 to the hydraulicfracturing tree 124 connected to the wellhead 120.

Turning to FIG. 18, with continuing reference to FIG. 17, it can be seenthat the flange 86 of the valve body 12 is connected to the flow-linecomponent 134, and the flange 88 of the valve body 12 is connected tothe flow-line component 136. The flow-line component 134 is connectedto, or part of, the flow iron section 116, including one or more of thepressurization manifold 122 connected to the hydraulic fracturing pump118, the hydraulic fracturing tree 124 connected to the wellhead 120,and the distribution manifold 126 connected between the pressurizationmanifold 122 and the hydraulic fracturing tree 124. Likewise, theflow-line component 134 is connected to, or part of, the flow ironsection 116, including one or more of the pressurization manifold 122,the hydraulic fracturing tree 124, and the distribution manifold 126.The connection of the valve body 12 between the flow-line components 134and 136 incorporates the plug valve 10 into the hydraulic fracturingsystem 114 so that, during the operation of the hydraulic fracturingsystem 114 to facilitate hydraulic fracturing of the subterraneanformation(s), the plug 26 is rotatable within the valve body 12 toselectively permit communication of the hydraulic fracturing fluid fromthe hydraulic fracturing pump 118 to the wellhead 120 via at least theflow iron section 116 and the fluid passage 32 of the plug 26.

The flow-line components 134 and 136 to which the plug valve 10 isconnected are illustrated in FIG. 18 as a pair of spools; however, theflow-line components 134 and 136 may each be, include, or be part of, avariety of flow-line components including, but not limited to, a valve,a spool, a flow block, a swivel block, another flow-line component, orany combination thereof. In addition, depending upon the particularcharacteristics of the flow iron section 116 to which the plug valve 10is connected, the flow-line components 134 and 136 and the plug valve 10may be oriented differently than the orientation illustrated in FIG. 18(i.e., horizontally, vertically, diagonally, etc.).

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the present disclosure.

In some embodiments, the elements and teachings of the variousembodiments may be combined in whole or in part in some or all of theembodiments. In addition, one or more of the elements and teachings ofthe various embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various embodiments.

In some embodiments, while different steps, processes, and proceduresare described as appearing as distinct acts, one or more of the steps,one or more of the processes, and/or one or more of the procedures mayalso be performed in different orders, simultaneously and/orsequentially. In some embodiments, the steps, processes and/orprocedures may be merged into one or more steps, processes and/orprocedures.

In some embodiments, one or more of the operational steps in eachembodiment may be omitted. Moreover, in some instances, some features ofthe present disclosure may be employed without a corresponding use ofthe other features. Moreover, one or more of the above-describedembodiments and/or variations may be combined in whole or in part withany one or more of the other above-described embodiments and/orvariations.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “left” and right”,“front” and “rear”, “above” and “below” and the like are used as wordsof convenience to provide reference points and are not to be construedas limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

Although some embodiments have been described in detail above, theembodiments described are illustrative only and are not limiting, andthose skilled in the art will readily appreciate that many othermodifications, changes and/or substitutions are possible in theembodiments without materially departing from the novel teachings andadvantages of the present disclosure. Accordingly, all suchmodifications, changes, and/or substitutions are intended to be includedwithin the scope of this disclosure as defined in the following claims.In the claims, any means-plus-function clauses are intended to cover thestructures described herein as performing the recited function and notonly structural equivalents, but also equivalent structures. Moreover,it is the express intention of the applicant not to invoke 35 U.S.C.§112, paragraph 6 for any limitations of any of the claims herein,except for those in which the claim expressly uses the word “means”together with an associated function.

What is claimed is:
 1. An apparatus, comprising: a valve body definingan internal cavity, a first passage, and a second passage; a plugdefining a third passage and being rotatable within the internal cavityto selectively permit communication of a fluid between the first andsecond passages via the third passage; and an insert extending withinthe internal cavity between the valve body and the plug, the insertdefining a first opening aligned with the first passage of the valvebody, a first interior surface, and a first sealing surface extendingaround the first opening and standing in relief against the firstinterior surface to sealingly engage the plug; wherein migration of thefluid into an annular region between the insert and the plug isprevented, or at least reduced, by the sealing engagement of the firstsealing surface with the plug.
 2. The apparatus of claim 1, wherein theinsert comprises a first segment including the first interior surface,the first opening, and the first sealing surface.
 3. The apparatus ofclaim 1, wherein the insert further defines a second opening alignedwith the second passage of the valve body, a second interior surface,and a second sealing surface extending around the second opening andstanding in relief against the second interior surface to sealinglyengage the plug.
 4. The apparatus of claim 3, wherein migration of thefluid into the annular region between the insert and the plug isprevented, or at least reduced, by the respective sealing engagements ofthe first and second sealing surfaces with the plug.
 5. The apparatus ofclaim 3, wherein the insert comprises a first segment including thefirst interior surface, the first opening, and the first sealingsurface, and a second segment including the second interior surface, thesecond opening, and the second sealing surface.
 6. The apparatus ofclaim 5, wherein the insert further comprises third and fourth segmentsinterconnecting the first and second segments so that, in combination,the first, second, third, and fourth segments surround the plug.
 7. Theapparatus of claim 1, further comprising: a flow iron section adapted tobe positioned between a hydraulic fracturing pump and a wellhead, theflow iron section comprising one or more of a pressurization manifoldconnected to the hydraulic fracturing pump, a hydraulic fracturing treeconnected to the wellhead, and a distribution manifold connected betweenthe pressurization manifold and the hydraulic fracturing tree; whereinthe valve body is connected to the flow iron section so that the plug isrotatable within the valve body to selectively permit communication of ahydraulic fracturing fluid from the hydraulic fracturing pump to thewellhead via at least the flow iron section and the third passage.
 8. Anapparatus, comprising: a valve body defining an internal cavity, a firstpassage, and a second passage; a plug defining a third passage and beingrotatable within the internal cavity to selectively permit communicationof a fluid between the first and second passages via the third passage;an insert extending within the internal cavity between the valve bodyand the plug, the insert defining a first opening aligned with the firstpassage of the valve body, a first interior surface, and a firstprojection at least partially defining the first interior surface; and aboot connected to the valve body and interlocked with the firstprojection of the insert to prevent, or at least reduce, rotation of theinsert relative to the valve body when the plug rotates within theinternal cavity.
 9. The apparatus of claim 8, wherein the firstprojection includes first and second side surfaces, and the bootincludes first and second edge portions extending adjacent the first andsecond side surfaces, respectively, of the first projection.
 10. Theapparatus of claim 9, wherein the boot further includes a third edgeportion extending between the first and second edge portions andadjacent the first interior surface of the insert.
 11. The apparatus ofclaim 8, wherein: the insert further defines a second opening alignedwith the second passage of the valve body, a second interior surface,and a second projection at least partially defining the second interiorsurface; and the boot is interlocked with the second projection of theinsert to prevent, or at least reduce, rotation of the insert relativeto the valve body when the plug rotates within the internal cavity. 12.The apparatus of claim 11, wherein: the first projection includes firstand second side surfaces, and the boot includes first and second edgeportions extending adjacent the first and second side surfaces,respectively, of the first projection; and the second projectionincludes third and fourth side surfaces, and the boot includes third andfourth edge portions extending adjacent the third and fourth sidesurfaces, respectively, of the second projection.
 13. The apparatus ofclaim 12, wherein the boot further includes: a fifth edge portionextending between the first and second edge portions and adjacent thefirst interior surface of the insert; and a sixth edge portion extendingbetween the third and fourth edge portions and adjacent the secondinterior surface of the insert.
 14. The apparatus of claim 11, whereinthe insert comprises a first segment including the first interiorsurface, the first projection, and the first opening, and a secondsegment including the second interior surface, the second projection,and the second opening.
 15. The apparatus of claim 14, wherein theinsert further comprises third and fourth segments interconnecting thefirst and second segments so that, in combination, the first, second,third, and fourth segments surround the plug.
 16. The apparatus of claim8, further comprising: a flow iron section adapted to be positionedbetween a hydraulic fracturing pump and a wellhead, the flow ironsection comprising one or more of a pressurization manifold connected tothe hydraulic fracturing pump, a hydraulic fracturing tree connected tothe wellhead, and a distribution manifold connected between thepressurization manifold and the hydraulic fracturing tree; and whereinthe valve body is connected to the flow iron section so that the plug isrotatable within the valve body to selectively permit communication of ahydraulic fracturing fluid from the hydraulic fracturing pump to thewellhead via at least the flow iron section and the third passage. 17.An apparatus, comprising: a flow iron section adapted to be positionedbetween a hydraulic fracturing pump and a wellhead, the flow ironsection comprising one or more of a pressurization manifold connected tothe hydraulic fracturing pump, a hydraulic fracturing tree connected tothe wellhead, and a distribution manifold connected between thepressurization manifold and the hydraulic fracturing tree; and a plugvalve connected to the flow iron section, the plug valve comprising avalve body and a plug, the plug defining a first passage and beingrotatable within the valve body to selectively permit communication of ahydraulic fracturing fluid from the hydraulic fracturing pump to thewellhead via at least the flow iron section and the first passage, thefirst passage having an inner diameter that is equal to, or greaterthan, about 5⅛ inches.
 18. The apparatus of claim 17, wherein the valvebody further defines second and third passages configured to communicatewith one another via the first passage of the plug when communication ofthe hydraulic fracturing fluid is selectively permitted from thehydraulic fracturing pump to the wellhead via at least the flow ironsection and the first passage.
 19. The apparatus of claim 18, whereinthe plug valve further comprises an insert extending between the valvebody and the plug, the insert defining an opening aligned with the firstpassage of the valve body, an interior surface, and a sealing surfaceextending around the opening and standing in relief against the interiorsurface to sealingly engage the plug.
 20. The apparatus of claim 18,wherein the plug valve further comprises: an insert extending within thevalve body between the valve body and the plug, the insert defining anopening aligned with the first passage of the valve body, an interiorsurface, and a projection at least partially defining the interiorsurface; and a boot connected to the valve body and interlocked with theprojection of the insert to prevent, or at least reduce, rotation of theinsert relative to the valve body when the plug rotates within the valvebody.